Method for manufacturing floor panels, as well as floor panel obtained by means of such method

ABSTRACT

Method for manufacturing floor panels, of the type, which comprises a top layer ( 4 ) on the basis of synthetic material ( 5 ) and which, at least at two opposite sides ( 7 A- 8 A;  7 B- 8 B), has profiled edge areas ( 9 ) that comprise at least coupling parts ( 10 ), whereby, for manufacturing the floor panels ( 1 ), one starts from a board-shaped material ( 6 ), characterized in that the floor panels ( 1 ) are formed at least partially by means of a laser treatment ( 11 ) of said board-shaped material ( 6 ).

This application claims the benefit under 35 USC 119(e) of U.S.provisional application No. 60/674,718 filed on Apr. 26, 2005.

This invention relates to a method for manufacturing floor panels, aswell as to a floor panel obtained by means of such method.

More particularly, the invention relates to a method for manufacturingfloor panels, of the type comprising a top layer on the basis ofsynthetic material, and in particular to floor panels mostly denominatedlaminate panels.

It is known that such floor panels can be of different construction.

Mostly, such laminate panels comprise at least a core, a decor, as wellas a top layer on the basis of synthetic material. The top layer mostlyconsists of a number of carrier sheets, for example, of paper, which aresoaked in resin, for example, a melamine resin, such as melamineformaldehyde. In such case, it is common to perform the laminate as aso-called “DPL” (Direct Pressure Laminate), whereby the top layer ispressed directly upon the core, or so-called “HPL” (High PressureLaminate), whereby the top layer as such is obtained by means of apressure treatment before providing the top layer as a whole on thecore. Also, other possibilities for forming such top layer are possible,for example, by making use of films, by applying a substance to behardened, such as a varnish or the like, or in any other manner. Thedecor mostly is printed, either directly on the core, with the possibleintermediary of a primer, or on one or more of the aforementionedcarrier sheets or on the aforementioned film.

It is also known that such floor panels can be applied for forming afloating floor covering. Hereby, these floor panels, duringinstallation, are coupled at their edges, either by means of a classicaltongue and groove connection, whereby these possibly are glued into eachother, or by means of mechanical coupling parts providing for a mutualcoupling of the floor panels in horizontal as well as in verticaldirections, for example, as described in the international patentapplication WO 97/47834. This document describes how the respectivecoupling parts can be formed while moving the floor panel over rotatingmechanical cutting tools. This method is also called continuous milling.

From the international patent application WO 01/96688, it is also knownto remove a material portion from the upper edge of such laminatepanels, such that the resulting surface forms, for example, a chamfer,whether or not then being covered by a decorative layer.

The present invention aims at a method for manufacturing floor panelsthat allows to obtain a better and/or less expensive and/or moreflexible and/or more reliable good finish. Also, the invention aims at afloor panel having such finish.

To this aim, the invention according to its first aspect relates to amethod for manufacturing floor panels of the type, which comprises a toplayer on the basis of synthetic material and which, at least at twoopposite sides, has profiled edge areas that comprise at least couplingparts, whereby, for manufacturing the floor panels, one starts from aboard-shaped material, with the characteristic that the floor panels areformed at least partially by means of a laser treatment of saidboard-shaped material.

Applying a laser treatment when forming floor panels in most cases,however, not always, means the elimination of at least one traditionaltreatment, for example, a treatment with a rotating mechanical cuttingtool, such as a milling cutter. A laser treatment requires lessmaintenance than, for example, the maintenance required by the wear of amilling cutter. Moreover, by means of a laser beam a thin and/or smoothcut is easier to obtain than, for example, with a saw or a millingcutter.

Preferably, for forming the floor panels of the board-shaped material,use shall be made of said laser treatment as well as of at least one ormore other treatments, said treatments being performed by means of oneor more mechanical cutting tools, for example, rotating mechanicalcutting tools, such as milling cutters or saws.

Said laser treatment can be performed on a board-shaped material, ofwhich during or after this treatment floor panels are obtained, as wellas to a board-shaped material having already the desired or almost thedesired dimensions of the respective floor panels.

Preferably, the laser treatment shall at least be applied for removing amaterial portion from the top layer of the floor panel. In a preferredform of embodiment, hereby the laser treatment and the aforementionedother treatments are combined such that, by applying the lasertreatment, the contact between, on the one hand, the cutting tool,cutting tools, respectively, and, on the other hand, the aforementionedtop layer is reduced, more particularly is reduced in respect to thecontact usually existing between such cutting tools and the top layer,when such floor panels were to be manufactured entirely by means ofmechanical cutting treatments of the board-shaped material. Reducingthis contact means a global reduction of the wear and a prolongation ofthe service life of the respective cutting tool, cutting tools,respectively. Limiting the mechanical contact with the top layer alsoeffects a better and more reliable quality of the floor panel. Thisadvantage is particularly present in floor panels with a rather brittletop layer, which breaks under the influence of mechanical contact, suchas, for example, a thermosetting top layer on the basis of melamineformaldehyde. More particularly, this advantage manifests itself inparticular in floor panels with top layers in which a wear-resistantmaterial, for example, corundum, is incorporated, as such materialcauses a high wear and tear with cutting tools and this disadvantage canbe considerably reduced by using a laser treatment.

In a particular preferred form of embodiment, by means of the lasertreatment, material is removed transversally through the top layer, overthe entire thickness thereof, preferably in the form of a cut extendingthrough the top layer. Hereby, it is advantageous to combine the lasertreatment and said other treatments such that, by applying the lasertreatment, the contact between the mechanical cutting tools and said toplayer is entirely excluded.

Preferably the aforementioned profiled edge area of the floor panels isformed at least partially by the laser treatment. Hereby, in aparticular preferred form of embodiment, at least a portion of the finalsurface of the profiled edge area is realized by means of the lasertreatment. It is not excluded to provide this profiled edge area with achamfer, whereby the final surface of this chamfer is formed at leastpartially by means of the aforementioned laser treatment.

Preferably, the final surface of the profiled edge area is also formed,at least partially, by the aforementioned other treatments. Hereby,then, for example, use shall be made of mechanical tools, for example,rotating milling tools and/or broaches. The use of mechanical tools forforming the profiled edge areas in floor panels, which at least comprisecoupling parts, as such is known, for example, from WO 97/47834.According to the present invention, however, as explained above, byapplying these tools in combination with a laser treatment, the contactbetween these tools and the top layer, however, can be limited or evenexcluded, which limits the wear and tear of the mechanical tools and mayeffect a more qualitative finishing.

It is known, when providing the profiled edge area and the couplingparts, to move the floor panels along mechanical tools, for example, byapplying the so-called continuous milling. In such configuration, withinthe scope of the present invention, it is recommended to fixedly attachthe laser lens and to move the floor panels also along the laser beam.However, it is not excluded to install the laser lens movable and/or tokeep the panel still. Said laser treatment preferably shall take placeon a line, and the possibly removed material portion preferably shall bedeeper than 0.2 mm, and even better deeper than 1 mm, such that theaforementioned material portion in depth direction comprises a largepart of the top layer and preferably continues to below the top layer.

Surprisingly, the inventors have found that, when forming said line,speeds can be reached that are comparable to the speeds reached incontinuous milling, for example, speeds of more than 100 m/min, or evenbetter more than 150 m/min. Speeds of more than 200 m/min are also notexcluded. Speeds of more than 100 m/min allow to install such lasertreatment in line with, for example, a milling process without reducingthe production speed.

When, by means of said laser treatment, the final upper edge of thefloor panel is formed, at least for a portion of the circumferencethereof, then a method fulfilling the first aspect of the invention willeffect an exceptionally high-quality edge finishing of the floor panel.Presumably, this is due to the fact that, when performing such lasertreatment, the top layer, at least at the height of said upper edge, canreach a temperature at which the synthetic material in the top layerbecomes plastic, such that, after performing the laser treatment, forexample, when the top layer cools off, a smooth upper edge is formed.

In a preferred form of embodiment, the final upper edge formed by meansof the laser treatment is performed with an undercut. This can berealized in any manner, for example, by inclining the laser beam,adjusting and/or positioning the focus of the laser treatment in respectto the workpiece, or similar.

As such, for the manufacture of floor panels, it is known to start froma board-shaped material upon which said top layer is present and wherebya top layer is concerned that comprises particles of a wear-resistantmaterial, for example, a ceramic material, such as Al₂O₃, SiC, diamond,etc. Applying a method according to the first aspect of the presentinvention for manufacturing such floor panels entails particularadvantages. With a treatment that is performed at the upper side of thefloor panel, it is expected that said particles are molten, vaporized orsplit, which effects a very high-quality treatment, in view of the factthat there are no, or almost no, projecting hard parts at the obtainedsurface. This is contrary to, for example, a milling process, wherebyeither the wear-resistant particles will be drawn out of the top layer,or the top layer around the hard particles will be removed, such thatthese particles form projecting hard parts on the obtained surface. Incomparison with a method whereby the same material portion of the toplayer is removed by means of a milling treatment, a laser treatment of atop layer with wear-resistant particles also includes a furtherrestriction of tool wear. Moreover, this method offers a more constantquality and, thus, a more reliable treatment.

In particular, the invention preferably shall be applied formanufacturing laminate floor panels comprising a core, whether or notcomposed of several layers or portions, a decor, as well as said toplayer of synthetic material. Preferably, the top layer of such laminatefloor panel then shows one or more of the following features:

-   -   that it consists of maximum three carrier sheets soaked in resin        and pressed upon the core, amongst which a printed decor layer;    -   that it is manufactured in the form of “DPL”;    -   that it is thinner than 0.5 mm.

Due to its small thickness, such top layer is exceptionally suitable forbeing subjected to laser cutting treatments.

When manufacturing floor panels, more particularly laminate floorpanels, in the traditional manner by means of rotating cutting tools,the top layer often is affected, and in case of a brittle top layer, forexample, of a thermosetting resin such as melamine formaldehyde, isbroken, which, for example, in the case of a DPL (Direct PressureLaminate), leads, amongst others, to a white line showing at the edge ofthe panels, which remains visible in an annoying manner in a floorcovering consisting of several of such floor panels. Coloring the edgesof such panels by means of a coloring agent in order to mask thesedisturbing edges is known. The present invention does not exclude that,during performing of a method according to the first aspect by means ofthe laser treatment, whether or not in combination with additionaltreatments, a thermal surface treatment is effected in at least aportion of the final surface of the profiled edge area. Preferably, thisthermal surface treatment consists at least in a discoloration. By meansof the heat development of a laser treatment and the depositing of aportion of the possibly removed material, a portion of the profiled edgearea, for example, the upper edge of the floor panel, can be coloreddark. This latter may also avoid that the edge of a laminate panelbecomes visible in a disturbing manner and may make the coloring of theedges by means of a coloring agent redundant. Another possible surfacetreatment consists at least of heating the surface by means of the lasertreatment, followed by smoothing the heated surface in the heatedcondition, in order to improve the smoothness of the surface.

According to another possible form of embodiment, the laser treatment isapplied at least, and in a particular form of embodiment is appliedsolely, for heating the surface of the floor panels, or at least aportion of the surface of the floor panels, with the intention ofinfluencing the mechanical and/or thermal and/or other features of saidportion. Such heating of the surface of the floor panels may result, forexample, in that a subsequent treatment of this heated and preferablystill warm portion, such as a treatment with a mechanical tool or atreatment with a laser beam or other beam, can be performed moreefficiently. So, for example, the wear of the mechanical tool may berestricted by this, or the energy coupling of the laser light into thesurface during the possibly following laser treatment may be influencedbeneficially. In the case that the floor panels relate to laminatepanels with a top layer on the basis of synthetic material, such heatingmay lead to an at least temporary local softening of the respective toplayer. This softening can be advantageously applied in particular whenthe top layer, apart from synthetic material, also comprises hardparticles, such as aluminum oxide (Al2O3). In that case a subsequenttreatment of the top layer with a mechanical tool experiences lessresistance in order to remove the hard particles together with thesoftened synthetic material, which can lead to a significant reductionof wear for the mechanical tool and a better finishing quality of thetop layer. So, for example, may the top layer be softened in order tosubsequently perform a mechanical cutting treatment through the softertop layer, for example, for forming the aforementioned profiled edgeareas.

As aforementioned, the laser treatment of the first aspect of theinvention, however, preferably results in an effective material removalfrom the top layer.

In a board-shaped laminate material, the material portion removed by thelaser treatment best continues into the core, for example, up to a depthof 0.7 to 2 mm below the upper side of the panel. It is not excludedthat said laser treatment is applied in order to remove solely amaterial portion from the core. By a laser treatment, cuts can beperformed, rounded or inclined parts can be provided at locations thatare difficult to reach or cannot be reached by cutting tools.

However, it is noted that, if one wants to avoid a depositing of theremoved material portion on the upper side of the panel, duringperforming the laser treatment, a blowing effect is provided, too, inorder to remove released material portions. The blowing effect can takeplace by means of, either, on the one hand, the cutting gas flowing fromthe nozzle (in English called “nozzle”) preferably with a pressure of 6bar or more, coaxially to the laser beam, or, on the other hand, anextern additional gas flow having, for example, also a pressure of 6bar. In order to obtain an optimum removal of the released material,preferably a blowing and/or suction effect is provided, which ischaracterized by one or more and preferably a combination of thefollowing features:

-   -   that there is at least a blowing effect substantially according        to a direction opposite to the direction with which the laser        front moves along the board-shaped material;    -   that there is at least a blowing effect substantially according        to a direction situated transversally to the direction with        which said laser front is moving along the board-shaped        material, and at the same time directed away from the finally to        be formed floor panel;    -   that there is at least a suction effect transverse, and        preferably substantially perpendicular, to the surface or the        decorative side of the floor panel to be formed, above the        already formed cut in the immediate proximity of the laser        front.

It is noted that by applying a blowing and/or suction effect with theabove-mentioned features, also the possible creation of nasty smells iscounteracted and the deposition of nasty-smelling particles on theproduced floor panels is excluded or minimized. According to a variant,instead of gas flows or in combination with a gas flow, rinsing cyclesmay be performed with a liquid medium, such as water, alcohol or thelike. These rinsing cycles may be particularly useful for preventing theoccurrence of said nasty smells.

In a particular preferred form of embodiment, one works with a lasersituated at an angle in respect to the surface of the board-shapedmaterial, whereby the arrangement at an angle is performed such that itfulfils at least one of the following and preferably a combination ofthe following features:

-   -   that the surface presented to the laser treatment, in other        words, the surface situated immediately in front of the laser        front, and the laser beam form an angle smaller than 90°, as        measured in a projection of the laser beam onto a plane situated        perpendicularly to the plane of the plate-shaped material and        extending according to the direction of advancement of the laser        front.    -   that the surface presented to the laser treatment and the laser        beam form an angle between 50 and 70°, for example, 60°;    -   that the surface presented to the laser treatment and the laser        beam form an angle according to any of the above-defined        possibilities, whereby next to the laser beam, a gas flow is        supplied to the floor panel by means of the same laser head, in        substantially the same direction.

Such inclination of the laser beam offers particular advantages inrespect to the quality of the laser treatment. It may lead to a moreefficient treatment, a qualitatively higher finish and/or lesscontamination by deposition of the removed material.

Applying the method according to the first aspect of the invention formanufacturing floor panels consisting at least partially of a materialon the basis of fibers, preferably wood fibers, which are consolidatedwith a binding agent, such as MDF or HDF, results in a broad range ofadvantages. So, by means of a laser treatment, for example, surfaceswithout protruding fibers can be obtained. It is known that laminatefloor panels often comprise a core of such material.

When performing the aforementioned treatment step according to the firstaspect of the invention, it is possible that the binding material at theheight of said edge becomes plastic and that this treatment step isfollowed by a treatment whereby the fibers at the height of the edge arepressed into the binding material by means of a pressing element, suchthat, when the binding material cools off, a smooth surface is obtained.

For performing a laser treatment according to the characteristics of thefirst aspect, a laser beam that is generated by a CO₂ laser with anoutput power of more than 1 kW and even better more than 2 kW or morethan 4 kW, is recommended. Preferably, hereby a laser pulse frequency isapplied that is higher than 10 kHz. Also other laser sources, such as,for example, a Nd-YAG laser, as well as other laser pulse frequencies,are possible. In a preferred form of embodiment, one works with a shortfocal distance, for example, a focal distance of less than 10 cm, suchthat the power of the laser can be concentrated onto the top layer ofthe floor panel in an optimum manner. By “focal distance”, the distancefrom the lens to the floor panel is meant. Preferably, the distance fromthe nozzle to the floor panel is kept small, too, for example, less than1.5 mm, or even better less than 1 mm.

It is noted that, when the laser treatment according to the inventiondoes not need to result in an effective material removal, but solelyneeds to result in a modification of the features of the beam-treatedportion of the floor panel, the power of the applied laser beam can belimited to 100 or 200 Watts.

Further is noted that various precautions can be taken in order topromote the coupling of the laser energy in the floor panel. So, forexample, in the case that the laser treatment is applied for treatingthe top layer of the floor panel, components can be present in thesynthetic material or the resin that promote such coupling-in of thelaser energy. So, for example, soot particles mixed into the resin mayhave a very beneficial effect. Also the application of hard particlesother than Al2O3, such as TiC, TiO2, diamond, BC4 is recommended, asthese have a more beneficial effect onto the coupling-in of the laserlight in the synthetic material of the top layer. Agents that preferablyare omitted as constituents and/or contaminants of the top layer are,for example, bauxite and barium sulfate.

The laser source preferably is erected external to the working area ofthe laser beam, for example, external to a machine in which both therespective laser treatment and another treatment step in the method areperformed. In such a configuration, the laser beam is lead towards thelens over a stabilized optical path, either by mirrors, as can be thecase with a CO₂ laser, for example, or by a glass fiber, as can be thecase with a Nd-YAG laser.

In a preferred form of embodiment, the laser beam, on its optical path,can be split into several beams by means of a so-called “beam splitter”.Splitting a beam originating from one laser source into at least twolaser beams is advantageous in the case of a method for manufacturingfloor panels, in view of the fact that in this manner two edges can betreated at the same time, whereas the space taken by laser sources, forexample, by CO₂ laser sources, remains limited. Preferably, the twoaforementioned laser beams treat two opposite sides of the floor panel.It is clear that in case a laser beam is split into several beams, therequired power of the laser source equals the sum of the required powerof the beams, plus the losses that occur as a result of the splitting.

It is clear that a method according to the first aspect of theinvention, instead of being applied with the aforementioned lasertreatment, can also be applied with another treatment, whereby thistreatment utilizes a beam other than a laser beam, such as, for example,a water beam, an electron beam, an ion beam, a plasma beam, a particlebeam, such as a sand beam, a spark beam, such as a series of sparks inelectro-discharge erosion, or the like. It is noted that, for example,for applying electrical sparks, use can be made of a somewhat conductivetop layer, such as is known, for example, from the international patentapplication WO 2004/050359.

A discoloration of an edge of a floor panel, such as explained inreference to the first aspect of the invention, can also be obtained byother heat sources than a laser beam. It is clear that such method, thediscoloration being obtained by whichever heat source, provides for thatthe appearance of said disturbing white line is entirely or partiallyavoided. Therefore, the present invention, according to a secondindependent aspect, relates to a method for manufacturing floor panels,more particularly laminate panels of the type comprising a core, adecor, as well as a top layer on the basis of synthetic material, withthe characteristic that the method comprises at least a treatment stepwhereby, by means of a heat source, a thermal treatment is given to atleast one edge, preferably an upper edge, of the laminate panels,whereby this thermal treatment comprises a discoloration of therespective edge. Preferably, such method is applied as a post-treatmentfor coloring light-colored edges that are obtained as a result of acutting treatment through the top layer of the laminate panels.

The inventors have found that setting the power of the heat source, e.g.of a laser beam, leads to setting the color of the treated edge. So, forexample, it is possible to vary the obtained color between light brownand dark brown or black. These colors are particularly interesting forthe post-treatment of floor panels imitating dark species of wood orstone. Such dark decors are present, for example, in imitations of woodspecies such as dark oak, wengé and the like, or in floor panels havinga shadow effect at the edge in their decor, as can be the case, forexample, when creating an optical illusion of an impression next to theedge, such as a chamfer, by means of the decor. In fact, with panelswith such dark decors, the aforementioned white line will appear mostdisturbing. Preferably, in such method, use is made of a laser beamhaving an adjustable power between 20 and 200 W, and even better between50 and 100 W. Obtaining said discoloration presumably occurs by means ofone or more of the following possibilities:

-   -   partially burning the top layer,    -   partially burning the core,    -   partially burning the decor,    -   depositing soot particles as a result of burning either the top        layer, or the core, or the decor,    -   starting a chemical reaction in the top layer or the core.

According to a deviating variant of a method according to the secondaspect of the invention, it is also possible that a chamfer provided atthe upper edge of the floor panel, or another surface obtained byremoving a material portion at the upper edge of the floor panel, isprovided with a color by means of a heat source. In a preferred form ofembodiment of such method, the coloration takes place simultaneouslywith the application of said surface. This can be, for example, by meansof a laser beam. It is noted that this deviating variant is preferablein particular with small surfaces, for example, with a dimension in onedirection that is smaller than 1 mm.

According to its third aspect, the invention also relates to a methodfor manufacturing floor panels, more particularly laminate panels of thetype comprising a core, a decor, as well as a top layer on the basis ofsynthetic material, with the characteristic that the method comprises atleast a treatment step, whereby, at least partially by means of a lasertreatment, a relief is applied on the upper surface of the floor panels.

The application of a relief on the upper surface of the floor panels,such as a relief that at least partially consists of a wood or a stonestructure, at least partially excludes a press treatment and the wear ofthe press plate related thereto. Moreover, due to the digital control ofa laser treatment, changing the relief is simple. Where traditionally apress plate had to be exchanged in order to provide another relief inthe top layer of the laminate material, according to the third aspect ofthe invention the laser treatment can be controlled by another programin order to obtain said other relief in the top layer.

According to a deviating form of embodiment of the third aspect, therelief that is provided on the upper surface by means of a lasertreatment, possibly in combination with the aforementioned wood or stonestructure, can also comprise a zone from which material has been removedin order to imitate a joint or a chamfer. This zone can be situated aswell at the edge of the floor panel as on the upper surface. In thelatter case, it may, for example, be applied for rendering theappearance of a laminate imitating several wooden planks or stone tilesmore realistic by removing material in the shape of a joint between therepresented planks or tiles.

The obtained relief, for example, the wood or stone structure and/or thejoint, thereafter may or may not be colored by means of a coloringproduct, for example, by means of a paint. The method, which is known assuch from the international patent application WO 2004/108436, forcoloring impressions provided in the top layer, can be applied to thisend.

It is noted that also according to the third aspect, the laser treatmentcan be performed both on a larger board-shaped laminate material as onboard-shaped laminate material already having the desired, or almost thedesired, dimensions of the intended floor panel.

According to a fourth aspect, the present invention relates to a methodfor manufacturing floor panels, more particularly laminate floor panelsof the type comprising a core, a decor, as well as a top layer on thebasis of synthetic material, whereby this method comprises at least thefollowing treatment steps:

-   -   producing a press plate that is provided with a relief,    -   forming the aforementioned floor panels, whereby said press        plate is at least applied for realizing, by means of said        relief, embossed portions in the upper surface of the floor        panels, and more particularly in a board from which subsequently        floor panels are formed,        with the characteristic that said relief in the press plate is        realized at least by means of a laser treatment.

Because a laser treatment is digitally controlled, the method accordingto this fourth aspect of the invention leads to a flexible manufacturingof floor panels. It allows, for example, to obtain a press plate with arelief, such as a wood or a stone structure, without utilizing anetching process. The etching process is little flexible, as it requiresmany intermediate steps. Traditionally, an etching process in factconsists of providing a mask of gel that is hardened selectively bymeans of light, and thereafter etching away the portions of the pressplate that are not covered by the mask. Obtaining a mask by selectivelyhardening gel can take place by covering gel portions that do not haveto be hardened by means of a film and, after exposing the gel to light,rinsing away the unhardened gel portions.

It is noted that the laser treatment can relate to a material-removing,such as laser milling, as well as to a material-depositing process, suchas laser cladding, selective laser sintering or selective laser melting.So, for example, in such manner material can be removed, which, forexample, is showing at a wood or stone structure, or in a selectivemanner material, such as hard particles, for example, Al₂O₃, or thelike, can be deposited, for example, in the form of a wood or stonestructure.

Applying the laser treatment as a part of a material-depositing process,amongst others, in the case of producing a press plate with a relief,leads to particular advantages. For producing a relief intended, forexample, for realizing embossed portions in the upper surface of thefloor panels in the form of a wood or a stone structure, the press plateonly has to be treated, or, in other words, material must be depositedonto the press plate only there, where the corresponding embossedportions, for example, the wood pores, have to be located at the floorpanel. This is contrary to a material-removing process that has to treatthe press plate everywhere, possibly with the exception of the locationswhere the corresponding embossed portions have to be located on thefloor panel.

In general, it can be stated, however, this does not always have to beso, that less than one-half of the upper surface of the floor panelcomprises embossed portions, such that a material-depositing process inmost cases leads to a shorter treatment time. Also the possibility todeposit another material, such as wear-resistant ceramic material, forexample, Al₂O₃, whether or not in a selective manner, is a particularadvantage of applying a material-depositing process. In this manner, thesurface, or certain portions of the surface, can be provided withparticular properties; for example, the wear resistance of the pressplate can be enhanced locally.

Applying a press plate according to the fourth aspect of this inventionfor forming a floor panel, or a board from which subsequently such floorpanels are formed, results, by means of the aforementioned relief, inembossed portions in the floor panel which, for example, represent awood or stone structure.

It is clear that the possibilities of the laser treatment are notlimited to providing a wood or stone structure. So, for example, also aprojection can be formed on the press plate that forms, during pressing,embossed portions on the upper surface or at the edge of the floorpanels, which form, for example, a chamfer or a joint.

It is noted that the present invention also relates to a floor panelwith the characteristic that, for the manufacture thereof, a methodaccording to one or more aspects of the invention is applied.

Further characteristics of the aforementioned methods and floor panelswill appear from the following described examples and the appendedclaims.

With the intention of better showing the characteristics of theinvention, hereafter, as an example without any limitative character,several preferred forms of embodiment are described, with reference tothe accompanying drawings, wherein:

FIG. 1, in a highly schematized manner, represents several treatmentsteps in a method for manufacturing floor panels according to thepresent invention;

FIGS. 2 to 5, at a larger scale, represent cross-sections according tolines II-II, III-III, IV-IV and V-V, respectively, in FIG. 1;

FIG. 6 shows a variant of the portion indicated by F6 in FIG. 2;

FIG. 7 represents a variant in a cross-section according to line VII-VIIin FIG. 1;

FIGS. 8 to 10 represent-more variants;

FIGS. 11 to 16 represent cross-sections similar to those of FIGS. 9 and10, however, for further variants;

FIGS. 17 and 18 represent another variant;

FIGS. 19 and 20, at a smaller scale, represent another method accordingto the invention;

FIG. 21 represents a highly enlarged and schematized representation ofthe area indicated by F18 in FIG. 5;

FIG. 22 represents another method according to the invention;

FIG. 23 represents a cross-section similar to that of FIG. 21, however,for a variant;

FIGS. 24 to 26 schematically represent still other variants according tothe invention;

FIGS. 27 to 30 illustrate another two variants of methods according tothe invention, whereby FIGS. 28 to 30, at a larger scale, represent theportion indicated by F28 in FIG. 27;

FIG. 31 represents still another preferred form of embodiment of amethod according to the invention.

FIGS. 1 to 5 represent a method for manufacturing floor panels 1. Moreparticularly, this relates to floor panels, 1, in particular laminatepanels, of the type comprising a core 2, a decor 3, as well as a toplayer 4 on the basis of synthetic material 5. For manufacturing thefloor panels 1, one starts from a board-shaped material, in this case,board-shaped laminate material 6. In the represented example, thisboard-shaped laminate material 6 already has approximately the desireddimensions of one floor panel 1. After forming the floor panels 1 fromthe board-shaped material, the floor panels 1 have profiled edgeportions 9, which at least comprise coupling parts 10, provided at leastat two opposite sides, and in this case at all four sides, namely thelongitudinal sides 7A-8A and the short sides 7B-8B. Hereby, the floorpanels 1 are formed at least partially by means of a laser treatment 11from the board-shaped material, in this case, thus, the laminatematerial 6. In this case, the floor panel 1 comprises profiled edgeportions 9 at both pairs of sides and the laser treatment 11 isperformed at each side.

For forming the floor panels 1, in the represented form of embodiment,apart from the aforementioned laser treatment 11, furthermore use ismade of one or more other, preferably machining treatments 12, by meansof one or more cutting tools 13, such as, for example, rotating ortranslating milling cutters 14, one or more saws 15 or the like, asdescribed in the following. More particularly, in the example of FIG. 1at each side 7A-8A-7B-8B one treatment step is performed by means of asaw 15 and two treatment steps are performed by means of a rotatingmilling cutter 14. Hereby, the so-called continuous milling isconcerned. As represented, the floor panel 1 hereby first is moved withits longitudinal sides 7A-8A along the laser beams 16 and the rotatingmilling cutters 13 in order to form the respective edge areas 9, afterwhich the floor panel 1 is subjected to similar treatments at its shortsides 7B-8B.

In order to avoid that each laser beam 16 is operating unnecessarily,the respective laser performing the laser treatment 11 can be switchedon and off by means of a signal detecting the presence or absence of afloor panel 1. Possibly, also a so-called “beam dumper” can be provided,which neutralizes such laser beam 16 when no floor panel 1 is presentand the laser beam 16 unexpectedly would remain beaming.

The aforementioned other treatments 12, in this case, the threesuccessive machining treatments at two opposite sides 7-8 of the floorpanel 1, preferably are performed in one and the same machine 17.Preferably, the laser treatment 11 also shall be performed in thismachine 17, although it is not excluded that particular advantages areobtained when the laser treatment 11, as represented in FIG. 1 for thetreatment of the short sides 7B-8B of the floor panel 1, takes placeoutside machine 17 with which said other treatments 12 are performed.When mounting the laser head 18 in a conventional processing machine, itis recommended to protect it as good as possible from dust created as aresult of said other treatment 12, which, of course, is less criticalwhen the laser head is situated outside machine 17. By “laser head 18”,that part of the laser installation is intended that comprises the lens19 and the so-called nozzle 20. Remaining parts of the laserinstallation, such as, for example, the laser source and the opticalpath, are not represented in the figures, however, preferably aresituated external to machine 17.

It is clear that the sequence of the treatments, such as, amongstothers, those represented in FIG. 1, can be varied at random and that,for example, first one or more other treatments 12 can be performed atthe board-shaped laminate material 6 before performing the lasertreatment 11, such as, for example, illustrated by the alternativearrangement 21 of the laser represented in dashed line in FIG. 1. Also,the laser treatment 11 can be followed by one or more other or similartreatments. It is also clear that it is possible to first treat theshort sides 7B-8B and thereafter the longitudinal sides 7A-8A of thefloor panel 1. Also the simultaneous or alternating performance oftreatments at the longitudinal and short sides is not excluded, and onecan also restrict oneself to processing only the longitudinal, or onlythe short sides, or only one side. Also, several laser treatments can beperformed at one side, whether or not realizing a common cut.

As represented in FIG. 2, the laser treatment 11 preferably is appliedat two opposite sides 7A-8A, and even better simultaneously at these twosides. Both laser beams applied thereby then preferably originate fromone laser source, the beam of which is split by means of a so-called“beam splitter”, which is known as such. It is clear that also more thantwo laser beams can be applied at the same time, or that more than twosides can be simultaneously treated, whether or not by laser beamsoriginating from one and the same laser source.

The laser treatment 11 represented in FIG. 2 is applied at least forremoving a material portion 22 from the top layer 4 and moreparticularly for forming a cut therein. Here, the treatment is alsoapplied for removing a material portion 22 from the core 2, in such amanner that the laser treatment 11 in this case also defines at leastthe profiled edge area finally to be realized. In the representedexample, the laser treatment 11 applies a cut in the decorative side 23of the floor panels 1, whereby a portion of the obtained surface 24forms the upper edge 25 of the floor panels 1.

It is noted that it is recommended to keep the distance FD between thelaser lens and the floor panel 1, the so-called focal distance, small,for example, smaller than 10 cm. In this manner, the laser energy isconcentrated in a small area, such that substantially solely the toplayer 4 and possibly the core 2 directly beneath the top layer 4 areremoved. Maintaining a short focal distance guarantees anenergy-efficient treatment of the top layer 4 of the floor panel 1.

The distance ND (“nozzle distance”) of the nozzle 20 to the floor panel1 is in the order of magnitude of 1 mm. Minor deviations that maymanifest themselves in the distance ND have only a small impact on theefficiency in general or the depth of such laser treatment 11 inparticular. So, for example, the typical deviations in the order ofmagnitude of 0.05 mm as a result of transporting the floor panels 1along the laser beam 16 will have no or almost no influence.

It is noted that, at least in the represented examples, the floor panels1 are processed with the decorative side 23 downward. It is clear thatwithin the scope of the invention, also other orientations of the floorpanels 1 and the pertaining treatments are possible. It is clear thatthe floor panels, during processing, are guided in a suitable manner.Guiding techniques are known as such and thus are not set forth ingreater detail.

Further is noted that during the performance of a treatment step inwhich a laser is applied, preferably a cutting gas 26 is used, forexample, compressed air, nitrogen or the like, which, by the nozzle 20,is supplied coaxially with the laser beam 16. The function of suchcutting gas 26 can be a double one. Firstly, this gas cools the lens 19;secondly, it can blow away a portion of the possibly removed material ofthe floor panel 1. Synergetic effects between the cutting gas 26 and thelaser treatment 11, by which the efficiency of the laser treatment 11increases, are not excluded.

In the represented arrangement, it is recommended to pay particularattention to keeping the laser lens 19 free of dust or any other dirt.This is possible by providing, for example, a continuous air streamabove the laser lens, such that the chance that an incident dustparticle remains on the laser lens is minimum. Such dust particle canlead to burning-in and increases the risk of the lens 19 bursting. It isalso possible to build a screen around the entire laser apparatus, outof which the laser beam 16 can be guided by means of a window. In thecase of a CO₂ laser beam, such window may consist, for example, of ZnSe.In the case of a Nd-YAG laser, the window may consist of glass orquartz. In connection therewith, it is also noted that a so-called“fiber laser” can be applied in such dust-rich environment in anadvantageous manner. Namely, such lasers can be built in the same powerrange as a CO₂ laser, however, offer a larger incorporation flexibilityfor the integration thereof in a machine 17. Nd-YAG and fiber lasers inparticular will be applied there, where the material portion 22 to beremoved does not contain any organic material.

As represented in FIGS. 3 to 5, the aforementioned laser treatment 11and the subsequent aforementioned other treatments 12, in this case theaforementioned three machining treatments, are combined such that byapplying the laser treatment 11, the contact between the cutting toolsand the aforementioned top layer 4 is reduced, or, as in this example,is avoided.

To this aim, as shown in FIG. 3, in a treatment following the lasertreatment 11, a material portion 27 can be removed, by means of a sawcut 28, up into the aforementioned cut, such that the surplus portion 29of the top layer 4, and possibly a portion of the core 2 beneath thistop layer 4, is separated from the floor panel 1 and thus the contactbetween cutting tools in subsequent treatments and the top layer 4 islimited and preferably even is avoided. FIGS. 4 and 5 show how the edgeregions 9 of the floor panels 1 thus can be formed further, for example,by means of rotating milling tools.

FIG. 6 shows that in a preferred form of embodiment, the laser beam 16is incident under an angle A<90°, preferably under an angle A=87° up to89°, onto the upper side 30 of the floor panel 1. In this manner, thelaser treatment 11 creates an inwardly inclined edge at the upper edge25 of the panels, whereby a good adjoining among adjacent floor panels 1in a floor covering can be obtained. FIG. 6 also represents anadditional extern gas flow 31, which is applied approximatelyperpendicular to the laser beam 16, directed away from the floor panel 1to be formed, in such a manner that a possible deposition is blown awayfrom the panel.

FIG. 7 represents a particularly preferred form of embodiment of themethod according to the first aspect of the invention. Hereby, the laserbeam 16 is directed considerably inclined in respect to the direction ofmovement 32 of the floor panels 1, such in a direction as representedand such as defined in the claims. Preferably, the laser beam 16 formsan angle B<80°, and even better an angle B in the order of magnitude of60°, with the upper side 30 of the floor panel 1. Surprisingly, theinventors have found that such inclination minimizes a potentialdeposition of the removed material, whereas the efficiency and qualityof the treatment remains acceptable. Presumably, the first is due to thefact that the cutting gas 26 blows away the removed material along thealready formed cutting line 33. It is noted that the invention does notexclude that the laser beam 16 also assumes other angles in respect tothe floor panel 1, for example, an angle B>90°.

Preferably, the forms of embodiment of FIG. 6 and FIG. 7 shall becombined in order to thereby obtain an optimum safeguarding againstdeposition on the floor panel 1 and to obtain a good adjoining of thefloor panels 1. It is evident that the aforementioned extra gas flow canbe applied in all forms of embodiment of all aspects.

FIG. 8 shows a variant of the method according to the first aspect ofthe invention, whereby first a laser treatment 11 and a saw cut 28 areperformed, as described herein above by means of FIGS. 2 and 3, however,such that the saw cut 28 does not reach up into the cut of the laserbeam 16, and therefore the surplus portion of the top layer 4 will notbe separated automatically. However, the saw cut 28 is performed suchthat the mutual distance d between this saw cut 28 and the cut providedby means of the laser beam 16 allows to break off the surplus portion 29of the top layer 4 by means of a pressure element. In case that themethod is applied to a floor panel 1, the core 2 of which substantiallyconsists of a material on the basis of fibers, such as, for example, MDFor HDF, it is preferred that the distance d in most cases is restrictedto 0.7 mm. This pressure element simply can consist of a guide 34varying its height in longitudinal direction, which pushes away thesurplus portion of the top layer 4 and effects the breaking off of thisportion of the core 2 of the floor panel 1.

FIGS. 9 and 10 represent a variant of a method according to theinvention. Hereby, first a saw cut 28 is provided in a side of the floorpanel 1, and thereafter, by means of a laser treatment 11, a cut 22 isperformed up into said saw cut 28, such that in this case, too, thesurplus portion of the top layer 4 is released, for example,automatically, or can easily be pushed away, as explained herein abovewith reference to FIG. 8. After these treatment steps, the profiled edgeareas 9 can be formed further, for example, as represented in FIGS. 4and 5, such that contact between the possible cutting tools and the toplayer 4 is limited or avoided.

FIGS. 11 and 12 show a variant, whereby the surplus portion of the toplayer 4 first, preferably to a major part, is removed by means of, forexample, a rough and, due to its simple straight shape, easy to grindmilling cutter 14, after which a laser treatment 11 is performed thatshapes the upper edge 25 of the panel. After both treatments, othertreatments, for example, treatments as represented in FIGS. 4 and 5,further shape the profiled edge area. During further shaping theprofiled edge area, the contact between the cutting tools and the toplayer 4 shall be limited, or even avoided.

As FIG. 13 shows, it is not excluded that the laser treatment 11 shapingthe upper edge 25 of the floor panel 1 is performed after forming thecoupling parts 10.

FIGS. 14 to 16 show another variant of the method of FIG. 1. Hereby, thesurplus portion 29 of the top layer 4 is only to a major part removed byproviding, for example, successively a cut 22 in the top layer 4 bymeans of a laser treatment 11 and removing a material portion 22, forexample, by means of a saw 15, up into the aforementioned cut. Hereafterthen preferably treatments follow analogous to those represented inFIGS. 4 and 5. It is noted that such saw in all described cases also maybe a milling cutter or another tool. The upper edge 25 of the floorpanel 1 then preferably can be formed in the last treatment step, forexample, also by a machining treatment, which then, however, will comeinto contact with the top layer 4. The possibly applied cutting tool 13during forming of the upper edge 25 of the panel preferably shallconsist of polycrystalline diamond (so-called “PKD”), and still betterof mono-crystalline diamond (so-called “MKD”). Also, cutting tools canbe applied, the cutting edge of which is coated with a hard layer, sucha chemically vapor-deposited diamond coating (in English known as “CVDtools” or “Chemical Vapor Deposition Tools”).

A method as represented in FIGS. 14 to 16 can be applied, for example,when the upper edge 25 of the floor panel 1 is formed by a chamfer,whereby this chamfer is entirely formed by a cutting tool 13.

FIGS. 17 and 18 illustrate a method whereby the aforementioned profilededge area comprises such chamfer 36 that is formed at least partially bythe aforementioned laser treatment 11. When performing such treatment,the laser beam 16 will meet the floor panel 1 in an inclined manner,namely at an angle A>90°, and still better at an angle A in the order ofmagnitude of 135°. As represented in FIG. 18, subsequently thereto alsoa saw cut 28 can be performed similar to the one represented in FIG. 3,such that the surplus portion of the top layer 4 is removed and thatduring the aforementioned other treatments 12 no, or only a limited,contact with the top layer 4 is made. Also, the laser treatment can beapplied exclusively for forming the chamfer, or for a portion thereof,whereas all other material is milled away, whether or not by means ofmilling treatments through the top layer, whereby the laser then onlyhas the purpose of forming the surface of the chamfer.

As illustrated in FIGS. 1 to 18, various variants of a method accordingto the first aspect of the invention are possible. It is clear thatwithin the scope of the invention, various treatment steps can becombined to a method for forming a floor panel 1 that entails one ormore of the above-mentioned advantages. Also, the mutual sequence of thevarious treatment steps can be changed at random, or laser beams can beapplied in several treatment steps.

FIGS. 19 and 20 show a variant of a method according to the first aspectof the invention. Contrary to the examples shown in FIGS. 1 to 18, thelaser treatment 11 of FIGS. 19 and 20 is performed at board-shapedlaminate material 6, from which during or after the laser treatment 11several floor panels 1 are obtained. In this case, material portions areremoved from the top layer 4 by means of several laser beams, andpreferably those removed material portions continue up into the core 2of the board-shaped laminate material 6. The other treatment 12, forexample, a saw treatment as represented by saws 36, following after saidlaser treatment 11, can, without contacting the top layer 4, divide theboard-shaped laminate material 6, for example, into smaller pieces ofboard-shaped laminate material 6 having approximately the desireddimensions of a floor panel 1. These smaller pieces then can besubjected to a method as represented in FIGS. 1 to 18.

FIG. 21 represents, highly enlarged, the top layer 4 of a floor panel 1.This top layer 4 is situated on top of the core 2 of the floor panel 1and consists of two carrier sheets soaked in resin 37, of which onecarrier sheet 38 carries a printed decor 3 representing, for example, awood pattern or a stone pattern, and forms the decor layer. The decorlayer is covered by a so-called overlay, which consists of a transparentcarrier sheet 39 also soaked in resin. The represented top layer 4 alsocomprises particles 40 consisting of a wear-resistant, preferablyceramic, material, such as Al₂O₃. The particles 40 are represented atthe bottom side of the overlay, however, it is clear that they can besituated everywhere in the top layer 4, however, preferably above thedecor 3. By the laser treatment 11, at the top layer 4 a smooth surface41 at the cut can be obtained, as on the obtained surface, asrepresented, no or almost no projecting hard parts are present. By thelaser treatment, the hard particles namely are molten, vaporized orsplit by a thermal shock related to the laser treatment, contrary toanother treatment 12, as, for example, milling, whereby the particlesare drawn in pieces out of the material and thus a rather rough cut iscreated.

The core 2 of the floor panel 1 preferably consists of a material on thebasis of fibers, preferably wood fibers, which are consolidated by abinding material, such as MDF or HDF. Preferably, when performing thelaser treatment 11, the binding material becomes plastic and is thistreatment step followed by a treatment whereby the fibers are pressedinto the binding material by means of a pressing element, such that,when the binding material is cooling off again, a smooth surface isobtained.

FIGS. 22 and 23 represent a method according, amongst others, the secondaspect of the invention. To this aim, this method comprises at least atreatment step in which, by means of a heat source, in this case a laserbeam 16, a thermal treatment is given to at least one edge, preferablyan upper edge 25, of the laminate panels, whereby this thermal treatmentincludes a discoloration 42 of the respective edge. FIG. 23 shows anenlarged view of the area indicated by F23 in FIG. 22 and shows that therespective discoloration preferably manifests itself at least on the toplayer 4, and, as represented, still better continues over the entire toplayer 4 even up to the core 2. The discoloration presumably is obtainedby the partial burning of the top layer 4 and/or the core 2 and/or thedecor 3 and/or the deposition of soot particles as a result of aburning, either of the top layer 4, or of the core 2 or of the decor 3.

Preferably, the heat treatment in the second aspect of the invention isperformed by means of a heat source, the power of which can be set infunction of the desired color of the respective edge. Hereby, avariation between light brown and black is preferred, as suchdiscoloration is desired in particular with dark decors.

FIGS. 24 and 25 illustrate a method according to the fourth aspect ofthe invention. To this aim, they represent a method comprising at leasttwo treatment steps.

FIG. 24 illustrates the first treatment step, namely producing a pressplate 43, which is provided with a relief 44. As represented in FIG. 24,this relief is realized at least by means of a laser treatment 11. Here,a laser treatment 11 is concerned that is digitally controlled andremoves material portions from a substrate in order to form theaforementioned relief on the press plate. The represented reliefconsists of several kinds of projections. These projections areintended, for example, for applying embossed portions in the floor panel1 in the shape of wood pores or the like, or in order to impress jointsinto the laminate material 6. The use of such relief is well known assuch.

FIG. 25 shows how such press plate then in a second treatment step isapplied for forming the aforementioned floor panels 1, in order torealize, by means of said relief, embossed portions in the upper surfaceof the floor panels 1, and more particularly in a board-shaped laminatematerial 6, from which subsequently such floor panels 1 are formed. Inthis case, this relates to a laminate material 6 of the DPL type,whereby in a press 45, at the upper side of a core 2, preferably awood-based core 2, the top layer 4, consisting in this case of twocarrier sheets soaked in resin, is directly pressed upon the core 2under the influence of temperature and pressure. At the underside of thecore 2, a backing layer 46 is provided, which also consists of a carriersheet soaked in resin.

According to a particular preferred form of embodiment, which isrepresented in FIG. 26, the press plate is provided with a relief bymeans of a material-depositing process, for example, a laser treatment,such as selective laser sintering, laser cladding or the like. By suchprocess, the relief can be built up in layers and this relief possiblymay consist of another material than the material of the press plate,for example, a material with particular features, such as awear-resistant material. As represented, this material 47 can besupplied in the form of a powder, after which it is consolidated at thedesired location, for example, under the influence of a laser beam 16.In such laser treatment, it is preferred to apply a Nd-YAG laser, incombination with a so-called scanner. This scanner, as known, consistsof a set of mirrors deflecting the beam towards the desired location ofincidence on the press plate.

It is noted that the various aspects of the invention can be combinedwith each other, as long as they are not contrary to each other, to forma method for manufacturing floor panels, which, when being performed,offers one or more of the above-mentioned advantages.

Further, it is noted that by the aforementioned movement of the floorpanels 1 over the laser beam 16, or the possible cutting tools of theaforementioned other treatment 12, a relative movement is intended andthat it is thus not excluded that both the floor panels 1 and the laserbeam 16 move and/or that, in a particular case, only the laser beam 16moves. The most preferred form of embodiment, however, is the onewhereby only the floor panels 1 are moving.

FIGS. 27 and 28 represent a method according to the invention, wherebythe laser treatment 11 is applied for manufacturing floor panels 1whereby a sunk edge area 48 is provided at one or more upper edges 25.More particularly, hereby the sunk edge area 48 is realized at least bymeans of a laser beam 16 beaming on the floor panel 1 at the height ofthe upper edge 25. As represented in FIG. 27, the laser beam 16 isapplied at least for heating and/or softening the top layer 4 and/or ofa material situated therebeneath. As represented in FIG. 28, then theheated or softened material, by means of a pressing roller 49 or otherpressing element, is transformed to a sunk edge area 48.

According to an alternative method that is illustrated in FIGS. 29 and30, the laser treatment of FIG. 27 is applied for removing a material 22from the top layer 4 and/or a material situated therebeneath, moreparticularly the core 2, in such a manner that the portion of the toplayer 4 situated at the upper edge 25 of the floor panel can be pushedtowards the core 2 or the like, such that in this case, too, a sunk edgearea 48 is created. It is noted that, when performing this method,preferably glue 50 is provided in the formed cut 22 in order to retainsaid portion of the top layer 4 in its transformed position, in otherwords, the position of this portion represented in FIG. 30.

FIG. 31 represents a method according to the invention whereby at leasta suction effect or suction operation 51 is created transverse, and inthis case perpendicular, to the surface or decorative side 23 of thefloor panel 1 to be formed, above the already formed cut 22 in theimmediate proximity of the laser front. By the immediate proximity ofthe laser front is meant there, where the smoke gasses and particlesrise or are deposited. As aforementioned, such suction operation 51preferably is combined with a blowing operation, such as, for example,the external gas flow 31 represented in FIG. 6.

According to a deviating form of embodiment of the invention, anotherbeam technique instead of “laser” shall be applied, where this ispossible. The laser beam can be replaced, for example, for cutting, by abeam of another medium, whereby medium has to be understood in itsbroadest sense, and whereby, amongst others, an ion beam, electron beam,liquid beam, gas beam, spark beam (electric discharge machining), or thelike are contemplated.

The present invention is in no way limited to the forms of embodimentdescribed by way of example and represented in the figures; on thecontrary may such method and such panel be realized according to variousvariants, without deviating from the scope of the invention. Theaforementioned saw cut 28, for example, may also be realized in anyother manner, possibly with a laser, too.

1. Method for manufacturing floor panels, of the type, which comprises atop layer having a composition based on a synthetic material and which,at least at two opposite sides, has profiled edge areas that comprise atleast coupling parts, comprising the steps: starting from a board-shapedmaterial, forming the floor panels at least partially by means of alaser treatment of said board-shaped material; removing a portion ofmaterial from the top layer by the laser treatment; and furthercomprising the steps of forming at least one profiled edge area at leastpartially by said laser treatment, and including, by the lasertreatment, forming a final upper edge of the floor panel, at least overa portion of the circumference of the floor panel; wherein for formingthe floor panels of the board-shaped material, use is made of said lasertreatment as well as of at least one or more other treatments, which areperformed by one or more mechanical cutting tools; and wherein saidlaser and other treatments are used to remove excess material whenforming the profiled edge area wherein at least two cuts are formed,including a first cut made by the laser treatment extending at leastpartially through the top layer, and a second cut made by at least onemechanical cutting tool, such that both first and second cuts border aquantity of excess material including at least a portion of the initialtop layer, and which quantity of excess material is entirely removablefrom the board-shaped material by the presence of both first and secondcuts, or is connected to the board-shaped material solely by a remainingweakened material portion, and is therefore readily removable from theboard-shaped material.
 2. Method according to claim 1, wherein the lasertreatment and the said at least one or more other treatments arecombined such that the contact between the one or more mechanicalcutting tools, respectively, and the top layer is reduced with respectto contact between such cutting tools and the top layer, when such floorpanels are manufactured entirely by mechanical cutting treatments of theboard-shaped material without using the laser treatment.
 3. Methodaccording to claim 1, wherein, by means of the laser treatment, materialis removed transversally through the top layer, over the entirethickness thereof.
 4. Method according to claim 3, wherein use is madeof any other treatment of the board-shaped material in addition to thelaser treatment, and further wherein the laser treatment and said othertreatment are combined such that, by applying the laser treatment,contact between mechanical cutting tools and said top layer is entirelyavoided.
 5. Method according to claim 1, said board like material beinga laminate including a core, wherein said laser treatment at least isapplied for removing a material portion from the core.
 6. Methodaccording to claim 1, including establishing, by means of the lasertreatment, at least a portion of a final surface of the profiled edgearea.
 7. Method according to claim 6, including providing said profilededge area with a chamfer, including forming a final surface of thechamfer at least partially by said laser treatment.
 8. Method accordingto claim 1, including providing, by means of the laser treatment, athermal surface treatment at least in one portion of a final surface ofthe profiled edge area.
 9. Method according to claim 8, includingcausing at least a discoloration by said thermal treatment.
 10. Methodaccording to claim 8, wherein the thermal surface treatment comprises atleast heating the surface by means of the laser, followed by smoothingthe heated surface in heated condition in order to enhance thesmoothness of the surface.
 11. Method according to claim 1, includingforming an undercut at the final upper edge by the laser treatment. 12.Method according to claim 1, including forming said at least oneprofiled edge area at a speed higher than 100 m/min.
 13. Methodaccording to claim 1, used for manufacturing floor panels, and startingfrom a board-shaped material upon which said top layer is present andthe top layer comprises particles of a wear-resistant material. 14.Method according to claim 1, used to make laminate floor panels, whichpanels comprise a core, a decor, and said top layer based on syntheticmaterial.
 15. Method according to claim 14, wherein the top layer hasone or more of the following features: that it comprises a maximum ofthree resin-soaked and pressed upon the core carrier sheets, including aprinted decor layer; that it is manufactured in the form of “DPL”(Direct Pressure Laminate); that it is thinner than 0.5 mm.
 16. Methodaccording to claim 1 used for manufacturing floor panels comprising atleast partially of a material based on fibers bonded together by abinding agent.
 17. Method according to claim 1, including, duringcarrying out the laser treatment, a blowing effect on the panels iscarried out to remove released material portions.
 18. Method accordingto claim 17, including, by means of the laser treatment, creating alaser front that is moved relative to the board-shaped material, andproviding a blowing and/or suction effect which comprises one or more,including a combination of, the following features: that there isprovided at least a blowing effect substantially in a direction oppositeto the direction with which the laser front moves along the board-shapedmaterial; that there is provided at least a blowing effect substantiallyin a direction extending transversally to the direction along which thelaser front is moving along the board-shaped material, and at the sametime the blowing effect is directed away from the final form of thefloor panel; that there is provided at least a suction effect extendingtransverse, and preferably substantially perpendicular, to a surface ofthe floor panel to be formed, above an already formed cut in theimmediate proximity of the laser front.
 19. Method according to claim 1,including, by means of the laser treatment, creating a laser front thatis moved in respect to the board-shaped material, and using a laser beamthat is disposed at an angle in respect to the surface of theboard-shaped material, so that the angled laser beam arrangementpossesses at least one of the following and preferably a combination ofthe following features: that the surface presented to the lasertreatment, namely the surface situated immediately in front of the laserfront, and the laser beam form an angle of less than 90°; that thesurface presented to the laser treatment, namely the surface situatedimmediately in front of the laser front, and the laser beam form anangle of between 50 and 70°; that the surface presented to the lasertreatment, namely the surface situated immediately in front of the laserfront, and the laser beam form an angle according to any of theconfigurations recited above, and, next to the laser beam, a gas flow issupplied to the floor panel by means of the same laser head generatingsaid laser beam, in substantially the same direction as the laser beam.20. Method according to claim 1, including moving said floor panelsalong the laser beam.
 21. Method according to claim 1, includingperforming the laser treatment by using a laser beam that is generatedby a CO₂ laser with a power of more than 1 kW.
 22. Method according toclaim 1, wherein said laser treatment is carried out using at least twolaser beams which originate from one laser source, the beam of which issplit.
 23. Method according to claim 22, wherein said two laser beamsare used to treat two opposite sides of the floor panel.
 24. Methodaccording to claim 1, wherein, instead of the laser treatment, anothertreatment is applied, using a beam other than a laser beam.